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Discussion Starter · #1 · (Edited)
This post will show all the steps required to properly install bkmoto.com HID projector headlight kit into the 2008+ Kasawaki Ninja 650R, The new ninja 1000, ER-6f, Z1000SX, 650

This kit will also work on the New 2012+ ninja 650 R, the headlight is slightly redesigned, but the process is exactly the same.

More information on this kit can be found on www.bkmoto.com

The kit will come with everything that you need to install the projectors, including all neccesary H7 adapters and H7 plugs which will plug into your OEM headlight plugs.

You will have both headlights on for low beams, and high beams, with super bright HID's and halo's

This project should take about a full day, or a nice weekend with lots of breaks.

Here is the complete kit:




Lets start!

Remove headlight, remove light bulbs from the headlight



Now, you will need to open your headlight.
To do this you will need to heat up the glue that holds the headlight together.
You have 2 choices, Either use the oven or buy a cheap heat gun (about $25 at any hardware store)

Heat gun Method:
Turn on the heat gun on high setting, hold the heat gun about 8" away from the seam and work your way around the headlight seam slowly for a few rounds.

Oven Method:
Preheat the oven to 225F degrees, place the headlight on a towel and into the center of the oven.
Bake the headlight for 8 minutes at 225F degrees, then remove the headlight.

Once headlight is hot, start to open it using flat head screw drivers, carefully open the little tabs that lock the headlight together and pry the headlight open.
If you are struggling, then the glue is not hot enough, as it should be fairly easy to open once the glue is hot.
You might need to reheat the headlight a few times untill the lens is off.





Remove the lens



Heat up the second lens and remove it, you might need to reheat the headlight for a few minutes if it cooled down while you were removing the first lens.



Remove the 3 screws on the back, on both sides of the headlight and remove the hardware





Painting the reflectors:
This step is optional, I opted to paint my reflectors matt black, as i like the blacked out headlight look.
If you plan on leaving the reflectors chrome, then skip this step.

To paint the reflectors you can either remove them and spray paint them or use painters tape to cover the headlight around the reflectors, then spray.

I removed my reflectors, by unscrewing the 2 rear adjustment knobs on the back of the headlight, and then popping the reflector out of the third mounting point.




I used this paint, and it came out great.



Mount reflectors back into the headlight



We are now ready to mount the projectors!



Remove the tiny screw on the back of the projector, which holds the HID bulb, then remove all hardware from the projector, except the big silicone washer.


Here is all the hardware that you need to mount the projectors


Insert projector into the light bulb hole, make sure that the gap on the front halo ring is facing down, this way the projector is properly oriented.



Fish all the wires from the projector, and place the H7 adapter plate





Place the lock washer



Tighten rear nut.
I recommend to use locktite on the rear nut, so it wont come loose from the bikes vibrations.

First tighten by hand, then use needle nose pliers. Hold the projector from the front while tightening the rear nut, this will keep the projector from spinning.
 
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Discussion Starter · #2 · (Edited)
Your projector is now mounted!



Mount the second projector using the same above steps



Projectors are mounted and we can close up the headlights.
Reheat the glue on the headlight body and lens with the heat gun, then press the headlight together.
Wrap some painters tape around the headlight tightly, and let it cool down for 30mins.

If using oven method, then put the lenses back onto the headlight, press them in lightly, not all the way.
Place headlight on a towel and into the oven at 225F for 5 minutes, remove hot headlight from the oven and press lenses firmly together.
wrap painters tape around tightly and let it cool down for 30mins.

Here is the result:




The rubber dust caps need to be slightly modified to fit the new hid bulb rubber seal.
Cut off this piece






Insert HID bulb into the dust cap, and secure the rubber seal





Now we need to fish the two white halo wires and the red/black wires through the remaining two holes on the rubber seal.
The white halo wires wont have a plug on them, but the red/black wires will, and the plug needs to be removed.

To remove the plug, you need to insert a needle or a hair clip into the small opening in the front of the plug just above the pin, and press down untill you get the pin out.
This part is a little tricky, especially the first few times you do it.



here is the pin that you will be removing, look at the little flap in the middle, this is basically what needs to be pushed down inside the plug for the pin to come out.


Once plug is removed, fish the wires through the two holes.


secure the HID bulb in the projector, using the tiny screw that you removed previously
and put the connectors back on the wires.







After you mount the headlight you can adjust the height of the beam with the two rear adjustment knobs.
I recommend simply to adjust them as far down as possible, which is pretty close to what it should be.
Be very careful and do not over spin the adjustment knobs, they are connected to very delicate plastic inserts, and if you strip them you wont be able to adjust them any more,
so if you feel more resistance, then it cant go any more.

.
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Discussion Starter · #3 · (Edited)
Here is the wiring expained:



Wiring without a switch:

1. Connect both White low beam + to Low beam + pigtail
2. Connect both Blue high beam + to high beam + pigtail
3. Connect both Halo red + to corner lights positive wires right halo to right corner light and left to left
4. Connect both Halo black - to corner lights negative wires right halo to right corner light and left to left
5. all other connections self explanatory.

Wiring with a switch:
Same as above, but there is a switch between the low beam + pigtail and the two white low beam + trigger wires






Here is the end result:









 

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IMO, this deserves a sticky. It's just something everyone always asks/wonders about. If not alone, maybe we could get a "DIY 650r" section.
 

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i was just looking do this install to my bike next, thanks for the post! i like the green but does it eluminate enough when driving?
 

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Discussion Starter · #7 ·
Amazing, detailed work. :D
Thanks!

IMO, this deserves a sticky. It's just something everyone always asks/wonders about. If not alone, maybe we could get a "DIY 650r" section.
I hope this gets stickied, as i see projector threads pop up very often with repeat questions.
and this will show pretty much everything there is to know about projector lights.

i was just looking do this install to my bike next, thanks for the post! i like the green but does it eluminate enough when driving?
The green halos are just for looks, they are not meant to eluminate the road.

The HID's inside the projectors are used to iluminate the road and they are very bright, much brighter than the stock headlights.
 

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OMG! I will be getting these! Is it $209 for the two, or each? Also does it include instructions? Are the HID bulbs easy to change out? (the site offers "Extra HIDS Light Bulbs" in the purchase screen) so wasn't sure if I'd want to try out different colors. What is the 55w HID upgrade that is also offered?
 

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Discussion Starter · #9 ·
OMG! I will be getting these! Is it $209 for the two, or each? Also does it include instructions? Are the HID bulbs easy to change out? (the site offers "Extra HIDS Light Bulbs" in the purchase screen) so wasn't sure if I'd want to try out different colors. What is the 55w HID upgrade that is also offered?
Yes, $209 includes the complete kit, like in the first picture, with two projectors.
As for installation instructions, you are looking at them. (this thread).

HID bulbs are easy to change out, but you will need to remove the wires from the rubber seal which is on the hid bulb, each time you change the bulb.

Standard hid's are 35w, all factory cars that come with hid's use 35w, and these projectors are very bright with 35w hids.

But if you want even brighter headlights the 55w upgrade will give you brighter hid's.
 

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Great write up

Are you installing a switch with these? And if so, can you hook the switch up for the angel eye halos only?
 

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I know you said you make sure the halo notch is facing down when you put the projectors in, but for safety's sake I think you should be doing a proper alignment before you loc-tite the rear nut, and definitely before you re-seal the housings.
 

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I'll be coming back to this....good write up
 

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I think this could be the best write up ever on this site. Excellent pics, superb detail and simple instructions... Kudos to you, sir!

Your HIDs look freaking awesome too.
 

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what size are those bulbs? I'm asking because I want to use 3000K HID bulb on one side but they don't have that option. So I want to get my own and replace it.
 

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Painting the reflectors, did you think about painting the reflectors on the DTR lights too? Or would that make the DTR lights a lot less bright?

I too am also interested in the on/off switch. I'd be interested in sometimes riding around with just Halos on during the day, and of course have the HIDs on for night time.

Now to decide... should I go with the blue halos or just the white... hmmm

Was planning on putting blue wheel stripes on my black 650, dunno if I should just get white lights and put white/silver stripes on then. Already have a pair of Blue LED DTR lights, and a pair of white ones.
 

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Discussion Starter · #18 ·
Are you installing a switch with these? And if so, can you hook the switch up for the angel eye halos only?
yep, when i get to the wiring portion i will show how to wire this kit with the halos as running lights and an on/off switch on the hid's low beam.

I know you said you make sure the halo notch is facing down when you put the projectors in, but for safety's sake I think you should be doing a proper alignment before you loc-tite the rear nut, and definitely before you re-seal the housings.
The H7 plate has a notch in it, so it pretty much takes care of the horizontal alignment, but those who want both cut off lines to be perfectly the same should power up the projectors prior to sealing the headlights and turn the projectors by hand untill the lines are completely the same horizontally.

what size are those bulbs? I'm asking because I want to use 3000K HID bulb on one side but they don't have that option. So I want to get my own and replace it.
here is a link to the bulbs
Aftermarket HID Bi-xenon Projector Lens Replacement Bulbs, For G8,G5,G3,G1 Lens | eBay


Painting the reflectors, did you think about painting the reflectors on the DTR lights too? Or would that make the DTR lights a lot less bright?


I too am also interested in the on/off switch. I'd be interested in sometimes riding around with just Halos on during the day, and of course have the HIDs on for night time.

Now to decide... should I go with the blue halos or just the white... hmmm

Was planning on putting blue wheel stripes on my black 650, dunno if I should just get white lights and put white/silver stripes on then. Already have a pair of Blue LED DTR lights, and a pair of white ones.
you can paint the little corner light reflectors, but then the lights will be hardly visible.

I'll be showing how to wire in a switch in the next steps of the how-to
 

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Discussion Starter · #19 ·
Finished up the post, and included the wiring diagrams, with and without a switch.
 
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